Test assembly for a circuit breaker

ABSTRACT

A test assembly for a circuit breaker with a single pole module having first and second conduction paths electrically isolated from each other via an interior wall of the module and a circuit board. The test assembly includes an axle at an upper portion of the interior wall and having a first end and a second end extending along opposite sides of the interior wall, a test actuation member configured to be actuated, and a spring in operable communication with the test actuation member and in signal communication with the circuit board. The spring contacts the test actuation member and the first end of the axle when the test actuation member is actuated, the axle conducts an electrical signal to the spring, and the spring provides a test signal to the circuit board initiating a test operation of the circuit breaker.

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates to circuit breakers. More particularly, to a test assembly used to test a tripping mechanism of a circuit breaker.

Circuit breakers provide overcurrent and short circuit protection & ground fault protection for electric power systems. A tripping mechanism is used to open separable contacts of the circuit breaker to interrupt current flow in a protected power system. In order to ensure the safe operation of circuit breakers, testing is performed periodically. Thus, circuit breakers are provided with a test button, by means of which it is possible to release the circuit breaker, in order to check the correct operation of the circuit breaker.

Circuit breakers generally are designed to minimize space therein. As such, contacts for testing ground fault and arc fault circuitry typically have been mounted directly onto a printed circuit board (PCB) of the circuit breaker. The contacts may be leaf springs that protrude from the PCB and are deflected into contact with one another in order to close the ground fault or arc fault protection circuit. There are several problems associated with the use of leaf spring contacts. For example, since such contacts are disposed internally within the circuit breaker, some type of linkage must be provided which operatively extends between the contacts and the exterior of the circuit breaker to permit the contacts to be closed from the exterior of the circuit breaker. Therefore, the use of the leaf springs may take up additional space within the circuit breaker and may be relatively expensive to incorporate into a circuit breaker.

It is thus desired to provide an improved test assembly for a circuit breaker that overcomes these and other shortcomings of the conventional test button.

BRIEF DESCRIPTION OF THE INVENTION

According to one aspect of the invention, a test assembly for a circuit breaker with a single pole module having a first conduction path and a second conduction path electrically isolated from each other via an interior wall of the single pole module and a circuit board. The test assembly includes an axle disposed at an upper portion of the interior wall and having a first end and a second end extending along opposite sides of the interior wall, a test actuation member configured to be actuated, a spring in operable communication with the test actuation member and in signal communication with the circuit board and configured to contact the test actuation member and the first end of the axle, such that when the test actuation member is actuated, the spring contacts the first end of the axle, the axle conducts an electrical signal to the spring, and the spring provides a test signal to the circuit board to initiate a test operation of the circuit breaker.

According to another aspect of the invention, a circuit breaker is provided. The circuit breaker including a single pole module having a first conduction path and a second conduction path electrically isolated from each other via an interior wall of the single pole module, a circuit protection device and a tripping mechanism in operable communication with the circuit protection device, a circuit board comprising a trip solenoid, a lever mechanism in operable communication with the trip solenoid, and a test assembly. The test assembly includes an axle disposed at an upper portion of the interior wall and having a first end and a second end extending along opposite sides of the interior wall, a test actuation member configured to be actuated, and a spring in operable communication with the test actuation member and in signal communication with the circuit board and configured to contact the test actuation member and the first end of the axle, such that when the test actuation member is actuated, the spring contacts the first end of the axle, the axle provides an electrical signal to the spring, the spring provides a signal to the circuit board, and the circuit board provides a trip signal to actuate the trip solenoid which causes the lever mechanism to actuate the tripping mechanism to trip the circuit breaker.

These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWING

The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of a circuit breaker in accordance with an embodiment of the invention.

FIG. 2 is a schematic diagram illustrating a residual current device (RCD) side of the circuit breaker shown in FIG. 1 in accordance with an embodiment of the present invention.

FIG. 3 is a schematic diagram illustrating a miniature circuit breaker (MCB) side of the circuit breaker shown in FIG. 1 in accordance with an embodiment of the present invention.

FIG. 4 is an exploded view of a test assembly for the circuit breaker shown in FIG. 1 in accordance with an embodiment of the present invention.

FIG. 5 is an exploded view of a portion of the module of the circuit breaker with respect to the test assembly in accordance with an embodiment of the present invention.

FIG. 6 is a side view of a test actuation member of the test assembly shown in FIG. 4 in accordance with an embodiment of the present invention.

FIG. 7 is a diagram of an axle of the circuit breaker in accordance with an embodiment of the present invention.

FIG. 8 is a diagram illustrating an initial state of the test assembly in accordance with an embodiment of the present invention.

FIG. 9 is a diagram illustrating an actuated state of the test assembly in accordance with an embodiment of the present invention.

FIG. 10 is a diagram illustrating an actuated state of the test assembly and a maximum travel of the spring when the test actuation member is actuated to its maximum limit in accordance with an alternative embodiment of the present invention.

FIG. 11 is a diagram illustrating an interface between the test assembly and a printed circuit board (PCB) of the circuit breaker in accordance with an embodiment of the present invention.

FIG. 12 is a diagram illustrating an interface between the test assembly and a printed circuit board (PCB) of the circuit breaker in accordance with an alternative embodiment of the present invention.

FIG. 13 is an exploded view of a test assembly for the circuit breaker shown in FIG. 1 in accordance with alternative embodiment of the present invention.

FIG. 14 is a diagram illustrating an interface between the test assembly shown in FIG. 13 and a printed circuit board (PCB) of the circuit breaker in accordance with an embodiment of the present invention.

FIG. 15 diagram illustrating an interface between the test assembly shown in FIG. 13 and a printed circuit board (PCB) of the circuit breaker in accordance with an alternative embodiment of the present invention.

The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1, a circuit breaker 100 for providing overcurrent and short circuit, and ground fault/earth leakage protection is disclosed. According to an embodiment of the present invention, the single pole module 110 is of a size of approximately 86 mm in height, 18 mm in width and 70 mm in depth, for example. The single pole module 110 is not limited to any particular dimensions and may vary accordingly. According to an embodiment of the present invention, the circuit breaker is a residual current circuit breaker with overcurrent protection (RCBO) having a single pole plus a neutral. However, the present invention is not limited to any particular type of circuit breaker and may vary accordingly. A test assembly 112 is also provided for the testing protection circuitry of the circuit breaker 100. The single pole module 110 includes first and second conduction paths electrically isolated from each other via an interior wall 111 of the single pole module 110. A first side (i.e., a residual current device (RCD) side 200 as depicted in FIG. 2) and a second side (i.e., an overcurrent protection (MCB) pole side 300 as depicted in FIG. 3) opposite the RCD side 200 are divided by the interior wall 111 (as depicted in FIGS. 2 and 4, for example). The interior wall 111 divides the space within the circuit breaker 100 and serves a shell or frame onto which components of the circuit breaker 100 are disposed. Details regarding the RCD side 200 and the MCB pole side 300 of the circuit breaker 100 will now be discussed below with reference to FIGS. 2 and 3.

FIG. 2 is a schematic diagram illustrating the RCD side 200 of the circuit breaker 100 shown in FIG. 1 in accordance with an embodiment of the present invention. The RCD side 200 provides earth leakage protection for the circuit breaker 100. In FIG. 2, the RCD side 200 includes a printed circuit board (PCB) 201 which includes a trip solenoid 203 and a current transformer 205 along with other electrical and electronic components. A lever mechanism 207 is also provided on the RCD side 200. The trip solenoid 203 and the current transformer 205 are arranged within on the PCB 201 such that the lever mechanism 207 is in operable communication with the trip solenoid 203. The lever mechanism 207 is also rotatable about a pin 217 and acts as an interface between the RCD side 200 and the MCB pole side 300 to enable a trip action of the circuit breaker 100 via the test assembly 112. The present invention is not limited to any particular arrangement of the components within the PCB 201 of the circuit breaker 100 and any other arrangement suitable for the purpose set forth herein may be used.

The test assembly 112 is also provided on the RCD side 200 of the circuit breaker 100 (as indicated by the dashed circle shown in FIG. 2). The test assembly 112 includes an axle 116 (as depicted in FIG. 7) disposed at an upper portion of the partition wall 111 and a test actuation member 114 configured to be actuated during the operation of the test assembly 112. According to an embodiment of the present invention, the test assembly 112 further includes a spring 115 disposed under the test actuation member 114 which is in operable communication with the test actuation member 114 and in signal communication with the PCB 201 and is used to perform a trip operation of the circuit breaker 100 during testing thereof.

An operation of an embodiment of the test assembly 112 will now be described with reference to FIGS. 2 and 3. The test assembly 112 is activated by pressing the test actuation member 114 in a downward direction (as indicated by arrow 1). Upon actuating the test actuation member 114, the spring 115 is in contact with the test actuation member 114 and pivots downward to contact a first end 116 a of the axle 116 (as indicated by arrow 2). Details regarding the axle 116 will be discussed below with reference to FIGS. 4 and 7. As mentioned above, the spring 115 is in signal communication with the PCB 201. When the spring 115 contacts with the axle 116, the axle 116 conducts an electrical signal to the spring 115 and the spring 115 provides a test signal to a test pin 218 of the PCB 201 to initiate a test operation of the circuit breaker 100. The PCB 201 then provides a trip signal to actuate the trip solenoid 203 (as indicated by arrow 3) and thereby causes movement of the lever mechanism 207 to rotate in a clockwise direction about the pin 217 (as indicated by arrow 4). The lever mechanism 207 includes a pin (not shown) on a side thereof which interfaces with the MCB pole side 300 to trip the circuit breaker 100. The interface between the RCD side 200 and the MCB pole side 300 will be discussed below with reference to FIG. 3.

FIG. 3 is a schematic diagram illustrating the MCB pole side 300 of the circuit breaker 100 shown in FIG. 1 in accordance with an embodiment of the present invention. Details regarding the MCB pole side 300 are described below in relation to the operation of the test assembly 112. As shown in FIG. 3, a toggle lever 301 is in mechanical communication with an operating mechanism 302 to control the position of a movable contact arm 304. A circuit protection device 305 and a tripping mechanism 307 in operable communication with the circuit protection device 305 for tripping the circuit breaker 100 are also provided. The circuit protection device 305 includes an electromagnetic protection device 308 (i.e., a coil) for short circuit protection and an arc distinguishing device 309 to extinguish arcs created during a trip operation of the circuit breaker 100. A thermal protection device 310 (i.e., a bimetallic strip) is also provided. In addition, an external tripping lever 311 is provided.

In FIG. 3, the movable contact arm 304 is shown in a “closed” position, which corresponds to an “on” position of the toggle lever 301, to allow the current to flow through a first conduction path 350 (depicted by a dashed line) of the circuit breaker 100. According to an embodiment of the present invention, in the first conduction path 350, current is supplied via a conductor 321 at a circuit connection portion 320. The current flows through the electromagnetic protection device 308 which is connected with the conductor 321. Since the movable contact arm 304 is in a “closed” position”, the current flows from a fixed contact 312 electrically connected with the electromagnetic protection device 308 through a movable contact 313 disposed on the movable contact arm 304 when contacting the fixed contact 312. The current then flows from the movable contact arm 304 to the thermal protection device 310 and continues through a conductor 322 to a second circuit connection portion 330. A main spring 315 is connected to a second end 116 b of the axle 116 and is in operable communication with the movable contact arm 304. According to an embodiment of the present invention, a second conduction path 360 (as depicted by a dashed line) is electrically connected with the first conduction path 350. In the second conduction path 360, when the movable contact arm 304 is in the “closed” position, current flows from the movable contact arm 304 to the main spring 315. As mentioned above, the main spring 315 is connected with the axle 116. According to an embodiment of the present invention, the axle 116 is included in the second conduction path 360 and is formed of a conductive material. Therefore, the current flows from the main spring 315 to the axle 116, and the axle 116 conducts an electrical signal when the test actuation member 114 is actuated. Additional details regarding the axle 116 will be described below with reference to FIG. 4.

Further, in FIG. 3, an activator 317 is in operable communication with the lever mechanism 207 (as shown in FIG. 2). As mentioned above, the lever mechanism 207 includes a pin (not shown) on a side thereof which extends through the interior wall 111 onto the MCB pole side 300. The pin of the lever mechanism 207 contacts the activator 317 and the clockwise rotation of the lever mechanism 207 causes the activator 317 to move in an upward direction (as indicated by the arrow 5). A hook 318 of the activator 317 is then released (as indicated by arrow 6) and a bias force is then applied to the main spring 315 to return it to a relaxed position (as indicated by arrow 7) which in turn causes the movable contact arm 304 to rotate in a counterclockwise direction to separate the fixed contact 312 and the movable contact 313 (as indicated by arrow 8). As a result, a link 319 of the operating mechanism 302 moves in a direction as indicated by arrow 9, thereby causing the toggle lever 301 to rotate about a pivot 320 in a counterclockwise direction (as indicated by arrow 10) and tripping the circuit breaker 100.

Additional details regarding the test assembly 112 will now be discussed below with reference to FIGS. 4 through 12. FIG. 4 is an exploded view of a test assembly 112 for the circuit breaker 100 shown in FIG. 1 in accordance with an embodiment of the present invention. In FIG. 4, the axle 116 includes a first end 116 a and a second end 116 b extending along opposite sides of the interior wall 111. That is, the first and second ends 116 a and 116 b are disposed on the RCD side 200 and the MCB pole side 300, respectively. The spring 115 includes a first end 115 a configured to contact the first end 116 a of the axle 116 when the test actuation member 114 is actuated, and a second end 115 b which is coupled with the PCB 201 to provide the test signal to the PCB 201. The main spring 315 is connected to the second end 116 b of the axle 116 on the MCB pole side 300. Referring back to FIG. 3, as mentioned above, the main spring 315 is in contact with the movable contact arm 304, and when the movable contact arm 304 is in a “closed” position as shown in FIG. 3, the axle 116 acts as a “conductor” and provides an electrical signal to the first end 115 a of the spring 115 to enable the spring 115 to provide a test signal to the PCB 201 (as depicted in FIG. 2), when the test actuation member 114 is actuated. According to an embodiment of the present invention, the test assembly 112 is not limited to the above configuration and may vary accordingly.

FIG. 5 is an exploded view of a portion of the module 110 of the circuit breaker 100 with respect to the test assembly 112 in accordance with an embodiment of the present invention. According to an embodiment of the present invention, as shown in FIG. 5, the single pole module 110 includes a receptor portion 113. The test actuation member 114 of the test assembly 112 is disposed within the receptor portion 113 of the module 110.

FIG. 6 is a side view of a test actuation member 114 of the test assembly 112 shown in FIG. 4 in accordance with an embodiment of the present invention. As shown in FIG. 6, the test actuation member 114 rests within the receptor portion 113 such that a predetermined gap of approximately 1.50 mm. remains between the test actuation member 114 and the single pole module 110. Therefore, the test actuation member 114 may be actuated downward within the predetermined gap.

Additional information regarding the axle 116 will now be discussed with reference to FIG. 7. FIG. 7 is a diagram of the axle 116 of the circuit breaker 100 in accordance with an embodiment of the present invention. As shown in FIG. 7, according to one embodiment of the present invention, the axle 116 is formed of a z-shape such that a middle portion thereof extends between the RCD side 200 and the MCB pole side 300 (as depicted in FIG. 4), connects with the main spring 315 and makes contact with the spring 115 when the test actuation member 114 is actuated. The axle 116 is not limited to any particular configuration and may vary accordingly. Additional details regarding the operation of the test assembly 112 will be discussed below in reference to FIGS. 8 through 10. FIG. 8 is a diagram illustrating an initial state of the test assembly 112 in accordance with an embodiment of the present invention. In FIG. 8, while in an initial position the first end 115 a of the spring 115 is of a predetermined distance from the first end 116 a of the axle 116. The predetermined distance is approximately 4.0 mm, for example. The second end 115 b of the spring 115 is in signal communication with the PCB 201 (as depicted in FIGS. 11 and 12 to be discussed below). An actuated state of the test assembly 112 will now be discussed with reference to FIGS. 9 and 10.

FIGS. 9 and 10 are diagrams each illustrating an actuated state of the test assembly in accordance an embodiment of the present invention. In FIG. 9, the test assembly 112 is actuated, by pressing the test actuation member 114 in a downward direction (as indicated by the arrow). When the test actuation member 114 travels a predetermined minimum distance of at least approximately 0.85 mm, the first end 115 a of the spring 115 contacts with the first end 116 a of the axle 116 to initiate a trip operation of the circuit breaker 100. As shown in FIG. 10, according to an embodiment of the present invention, the test actuation member 114 is capable of traveling a predetermined maximum distance of approximately 1.50 mm (as indicated by the arrow). When the test actuation member 114 is actuated the maximum distance, the spring 115 over travels a distance of approximately 1.7 mm beyond the axle 116. The test actuation member 114 of the present invention is not limited to traveling any particular distance and may vary accordingly. The interface between the test assembly 112 and the PCB 201 of the RCD side 200 will now be discussed below with reference to FIGS. 11 and 12.

FIG. 11 is a diagram illustrating an interface between the test assembly 112 and the PCB 201 of the circuit breaker 100 in accordance with an embodiment of the present invention. As shown in FIG. 9, the second end 115 b of the spring 115 is in signal communication with the test pin 218 of the PCB 201 via a dedicated conductor 119. The present invention is not limited to any particular manner in which to electrically connect the test assembly 112 to the PCB 201 and therefore any suitable method may be utilized. FIG. 12 is a diagram illustrating an interface between the test assembly 112 and PCB 201 of the circuit breaker 100 in accordance with an alternative embodiment of the present invention. In FIG. 12, the second end 115 b of the spring 115 is directly connected with the test pin 218 of the PCB 201.

As mentioned above, the present invention is not limited to any particular arrangement of the test assembly 112. FIG. 13 is an exploded view of a test assembly for the circuit breaker shown in FIG. 1 in accordance with an alternative embodiment of the present invention. Some of the features of the test assembly are the same as the test assembly 112 shown in FIG. 2 for example, therefore, the same reference numerals are used for purpose of illustration. As shown in FIG. 13, a test assembly 130 includes a spring 120 having a first end 120 a disposed between the test actuation member 114 and the first end 116 a of the axle 116. When the test actuation member 114 is actuated, it contacts the spring 120, which in turn causes the spring 120 to contact the first end 116 a of the axle 116. The second end 120 b of the spring 120 is in signal communication with the PCB 201 in a same manner as previously discussed above with reference to FIGS. 11 and 12. As shown in FIGS. 14 and 15, respectively discussed below.

In FIG. 14, the second end 120 b of the spring 120 is in signal communication with the test pin 218 of the PCB 201 via a dedicated conductor 119. On the other hand, according to another embodiment of the present invention, as shown in FIG. 15, the second end 120 b of the spring 120 may directly connected with the test pin 218 of the PCB 201.

Embodiments of the present invention provides a z-shaped axle to secure the main spring on the MCB pole side of the single pole module and act as a conductor when the test actuation member is actuated, to thereby provide a electrical signal to initiate a trip operation of the circuit breaker via the test assembly. Since the z-shaped axle is an extension of the axle holding the main spring on the MCB pole side, the present invention enables clearance within the circuit breaker to be maintained with reduced manufacturing costs associated with the circuit breaker.

While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. 

1. A test assembly for a circuit breaker with a single pole module having first and second conduction paths electrically isolated from each other via an interior wall of the single pole module and a circuit board, the test assembly comprising: an axle disposed at an upper portion of the interior wall and having a first end and a second end extending along opposite sides of the interior wall; a test actuation member configured to be actuated; a spring in operable communication with the test actuation member and in signal communication with the circuit board and configured to contact the test actuation member and the first end of the axle, such that when the test actuation member is actuated, the spring contacts the first end of the axle, the axle conducts an electrical signal to the spring, and the spring provides a test signal to the circuit board to initiate a test operation of the circuit breaker.
 2. The test assembly of claim 1, wherein: the spring comprises a first end configured to contact the first end of the axle when the test actuation member is actuated, and a second end coupled with the circuit board to provide the test signal to the circuit board.
 3. The test assembly of claim 2, wherein a main spring which operates a tripping mechanism of the circuit breaker is connected to the second end of the axle.
 4. The test assembly of claim 3, wherein the spring is in signal communication with the circuit board via a dedicated conductor.
 5. The test assembly of claim 3, wherein the spring is directly connected with the circuit board.
 6. The test assembly of claim 3, wherein when the test assembly is in initial state, the first end of the spring is of a predetermined distance from the first end of the axle.
 7. The test assembly of claim 6, wherein the test actuation member is configured to travel a predetermined minimum distance to initiate the test operation.
 8. The test assembly of claim 6, wherein the test actuation member is capable of traveling a predetermined maximum distance such that the spring over travels beyond the axle.
 9. The test assembly of claim 1, wherein the axle is formed of a z-shape.
 10. A circuit breaker comprising: a single pole module having a first conduction path and a second conduction path electrically isolated from each other via an interior wall of the single pole module; a circuit protection device and a tripping mechanism in operable communication with the circuit protection device; a circuit board comprising a trip solenoid; a lever mechanism in operable communication with the trip solenoid; and a test assembly comprising: an axle disposed at an upper portion of the interior wall and including a first end and a second end extending along opposite sides of the interior wall; a test actuation member configured to be actuated; a spring in operable communication with the test actuation member and in signal communication with the circuit board and configured to contact the test actuation member and the first end of the axle, such that when the test actuation member is actuated and the spring contacts the first end of the axle, the axle conducts an electrical signal to the spring, the spring provides a test signal to the circuit board, and the circuit board provides a trip signal to actuate the trip solenoid which causes the lever mechanism to actuate the tripping mechanism to trip the circuit breaker.
 11. The circuit breaker of claim 10, wherein: the spring comprises a first end which contacts the first end of the axle when the test actuation member is actuated, and a second end coupled with the circuit board to provide the test signal to the circuit board when the first end of the spring contacts the first end of the axle.
 12. The circuit breaker of claim 11, further comprising: a main spring which operates a tripping mechanism, wherein the main spring is connected to the second end of the axle.
 13. The circuit breaker of claim 12, further comprising: an activator in operable communication with the lever mechanism; a fixed contact and a movable contact; and a movable contact arm carrying the movable contact, in operable communication with the activator, wherein when the lever mechanism operates, the activator moves and causes the movable contact arm to be rotated by the main spring to separate the fixed contact and the movable contact.
 14. The circuit breaker of claim 13, wherein the axle is formed of a conductive material.
 15. The circuit breaker of claim 14, wherein the spring is in signal communication with the circuit board via a dedicated conductor.
 16. The circuit breaker of claim 14, wherein the spring is directly connected with the circuit board.
 17. The circuit breaker of claim 14, wherein when the test assembly is in an initial state, the first end of the spring is of a predetermined distance from the first end of the axle.
 18. The circuit breaker of claim 17, wherein the test actuation member is configured to travel a predetermined minimum distance to initiate a test operation of the circuit breaker.
 19. The circuit breaker of claim 17, wherein the test actuation member is capable of traveling a predetermined maximum distance such that the spring over travels beyond the axle.
 20. The circuit breaker of claim 10, wherein the axle is formed of a z-shape. 